Overview
Timeframe: 2024-2025
Category: Manufacturing Engineering / Asset Optimization
Retired legacy lines and reused viable stations to launch new processes without buying new equipment or pausing production.
The Problem
New products needed different steps, but space, budget, and time were tight. We had to harvest and redeploy what we already owned while keeping adjacent lines running.
Constraints
- No unplanned downtime on nearby equipment
- Validation-ready processes for the new builds
- Minimal outside vendor support and short deadlines
Approach
I ran the decommission-to-reuse cycle end to end:
- Planned and executed controlled teardown of idle automation
- Salvaged mechanical, electrical, and controls hardware for new stations
- Redesigned sequences, fixtures, and PLC logic for new parts
- Validated function with production and quality teams before release
Tools & Technologies
PLC Programming
Process Validation
Mechanical Tooling
System Integration
Manufacturing Docs
Impact
- Launched new product steps without new capital
- Freed floor space while keeping production online
- Built repeatable playbook for future lifecycle changes
Key Learnings
- Decommissioning can be a source of parts, not just scrap.
- Close coordination with quality keeps reused assets release-ready.
- Tight sequencing is essential when working beside live production.